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Botttom line up front - <p>What does the green o-ring do that is installed before the spline coupling onto the transmission output shaft?<p>What is the primary seal for keeping fluid in the transmission housing at the output shaft?<p>Thanks - Ben<p>--------------------------------------------------------------------------<p><br>More info:<br>I replaced the spline coupling 8 months ago and have developed at least one leak in the past 6 months. All seals were replaced at time of coupling replacement.<p>I checked the fluids about 4 months ago and the angle gear was full, but the trans was 0.5 litres low (most of this I attribute to fluid lost during the spline coupling replacement). I topped off the trans and have driven for another 4 months with the regular 2-3" diameter drip circle on a daily basis.<p>I got under it yesterday and took note of the drip locations.<p>1) Drop forming off of the flat surface on the underside of the angle gear<br>2) Drop forming off of the lowest angle gear flange lobe at the transmission interface<br>3) Two drops forming, off of the outboard edge of the transmission, just below the drain port<p>I wiped everything dry and then waited until today to go take another look. <p>1) Did not re-appear - Drop on the flat surface on the underside of the angle gear<br>2) Re-appeared - Drop forming off of the lowest angle gear flange lobe at the transmission interface<br>3) Re-appeared - Two drops forming, off of the outboard edge of the transmission, just below the drain port (these drops left a trail and told me that they came from the same place as the drop in #2 above)<p>I definitely have a fairly steady leak from within that little spline coupling zone, fortunately.....the fluid isn't that tell-tail rust color.<p>I looked up at the underside of the turbo on the intake side and it is also wet.<p>What is the likliehood of a turbo oil line leak dripping down onto the top of the angle gear and forming the drop on the angle gear lower surface that did not reappear? I neglected to smell the first drop, since it didn't re-appear I am thinking it is something more operationally created.<p>The seals on the angle gear that are externally visible do not appear to be leaking, however the rear output cone section (of the housing) on the angle gear IS wet and is obviously represents the broad "trail" where the fluid is coming from that formed on the angle gear bottom surface. It does not look like it is coming from the prop shaft output seal. <p>How long would this thing vent out of the breather?? Till it is dry? I neglected to upgrade the breather when I did the coupling.....can I still get at it now? One other note.....the seam where the angle gear halves meet looks like it may be source of seepage.....I didn't split the case halves when I did the coupling and the seals.<p>For the seals that I cannot see, both on the angle gear and the transmission at the splined coupling......obviously the angle gear has to come out for inspection. If one of these seals has obviously failed, then the fix would be rather simple replacement. What about that green o-ring that went on the trans output shaft before the spline coupling?? Anyone know what it does? It seemed odd when I pushed it on. <p>Also....there are obvioulsy some other seals to keep the fluid in the trans....since I didn't get a full two liters dumped on me when I pulled the angle gear/spline coupling and related (2) seals....anyone seen the guts of an M66 to understand what is really keeping the fluid in there? I definitely got a little rush of fluid when I removed the large lip seal on the transmission side, but it only appeared to be what was collecting in the bottom of that transmission output shaft/spline coupling cavity. I'm concerned that the problem may be deeper in the trans.<p>I'm also a little concerned about having to remove the new coupling, obviously the old one was a PITA to get off, destructively....and I don't want to sacrifice the new one that is still intact to inspect that green o-ring.....<p>Any help or recommendations are very much appreciated......I'll post back tomorrow with how low the trans is after I top it off......but I'm thinking now that it may be worthwhile to save the $$ in fluid, drain the trans completely....have the old fluid analyzed for metal content to see if I've really damaged the internals with running it low on fluid, pull the angle gear to inspect the seals and take it from there.<p>This car is f-ing sweet but after the slave cylinder, spline coupling and some bushings I'm realizing how expensive it is to drive a special vehicle.<br><BR><BR>
<i>Modified by martinbs at 7:16 AM 8-22-2009</i>
 

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Re: Trans / Angle Gear / Turbo Leaks (martinbs)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>martinbs</b> »</i></TD></TR><TR><TD CLASS="quote"><br>This car is f-ing sweet but after the slave cylinder, spline coupling and some bushings I'm realizing how expensive it is to drive a <B>under-engineered Volvo out-of-warranty</B>.<br> </TD></TR></TABLE> <p>fixed
 

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Re: Trans / Angle Gear / Turbo Leaks (martinbs)

I'll defer to the experts about the transmission seals, but they are supposed to be replaced when you do spline replacement. It is not clear to me from your post which ones (all?) you did replace.<p><TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>martinbs</b> »</i></TD></TR><TR><TD CLASS="quote"><br>.....the seam where the angle gear halves meet looks like it may be source of seepage.....I didn't split the case halves when I did the coupling and the seals.<br></TD></TR></TABLE><p>This seal is a very common source of leaks, far more common that the other mechanisms you mention. I'd concentrate my attention there, and if confirmed, do the all too common "angle gear reseal"<p><TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>martinbs</b> »</i></TD></TR><TR><TD CLASS="quote"><br>This car is f-ing sweet but after the slave cylinder, spline coupling and some bushings I'm realizing how expensive it is to drive a special vehicle.<br></TD></TR></TABLE><br>I'm only up to step one in your list, but <br><IMG SRC="http://4.bp.blogspot.com/_cUgUYFPgeuM/SfHlkfI3RlI/AAAAAAAAADo/KNSWr5_0KaQ/s320/Amen-Brother.jpg" BORDER="0">
 
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